A wing and a prayer: outsourcing at Boeing



Thu, Jan 20, 2011

On a blustery and drizzly December afternoon in the Pacific Northwest, about 20 airplanes sat engineless and inert near the runway at a Boeing manufacturing plant. Huge, yellow blocks hung from the wings of some planes to substitute for the weight of absent engines.

Every few minutes, the heavy clouds parted to give a glimpse of blue skies over Everett, Washington, just north of Seattle. Then new clouds rolled in.

The parked planes are 787-8 Dreamliners, the world's first commercial aircraft with a body and wings made largely of lightweight carbon-composite materials instead of aluminum. Someday these sleek, fuel-efficient machines -- already painted in the liveries of their airline customers -- may change the face of air travel and plane-making.

But not today.

The program that produced these unfinished 787s is nearly three years behind schedule and, by some estimates, at least several billion dollars over budget. Dreamliner flight tests were halted in November after an electrical fire aboard a test plane. The tests resumed in December, and the company later announced yet another delay for the delivery schedule. The new ETA is sometime this summer. the rest image

Instead of drawing primarily from its traditional pool of aircraft engineers, mechanics and laborers that runs generations deep in the Puget Sound region around Seattle, Boeing leads an international team of suppliers and engineers from the United States, Japan, Italy, Australia, France and elsewhere, who make components that Boeing workers in the United States put together.

"Do you see the stupidity in that?" said James Williams, an imposing 43-year-old who has been employed by Boeing for 15 years, mostly working in factory safety.